Rapid Prototype Castings
(Using Lost Foam Process to Make Prototypes)

Example Aluminum Part
Air Intake Manifold CADD Data

Example Aluminum Part
Air Intake Manifold Patten Pieces Cut

Example Aluminum Part
Air Intake Manifold Partial Pattern Assembly

Example Aluminum Part
Air Intake Manifold Partial Pattern Assembly

Example Aluminum Part
Air Intake Manifold Casting

Example Aluminum Part
Air Intake Manifold Casting

Example Aluminum Part
Engine Block Prototype Casting Project

Example Aluminum Part
Engine Block Segment D Bottom View

Example Aluminum Part
Engine Block Made from Pattern Segments

Example Aluminum Part
Engine Block Segments Showing Cored Areas

Example Aluminum Part
Engine Block Segments Showing Cored Areas

Example Aluminum Part
Water Cooled Manifold Exterior Surfaces

Example Aluminum Part
Water Cooled Manifold Interior Surfaces

Example Aluminum Part
Water Cooled Manifold Casting Engine Face

Example Aluminum Part
Water Cooled Manifold Show Face

Example Aluminum Part
Prototyping Die Castings Using Lost Foam Prototyping

Example Aluminum Part
Thin Wall Sections

Example Iron Part
Agricultural Combine Part - Blade Section

Example Iron Part
Agricultural Combine Part - Net Shaped Blades

Summary

Status

• Virtually Any Form Possible.
• Patterns Reflect Molded Foam Parting and Glue Lines.

Status with Aluminum Castings

• Success in Range of Parts.
• 90% Cast on First Article.
• Detail and Surface Finish Similiar to Molded Foam

Status with Iron Castings

• 75% Cast on First Article.
• Detail and Surface Finish is Lower Quality than Molded Foa